Lesson Plan

• Identify the principal limitations of operational strategies used to achieve lean production.
• Evaluate how each limitation can affect lean‑production goals such as waste reduction and flow efficiency.
• Compare hybrid approaches that mitigate these constraints.
• Apply a simple value‑stream mapping exercise to decide whether a product family is suitable for a pure or hybrid lean strategy.

• Projector and screen
• PowerPoint slides covering lean concepts and limitations
• Handout containing the limitation table
• Whiteboard and markers
• Sticky notes for group brainstorming
• Laptop with internet access for short case‑study videos

Start with a quick poll: “Which aspect of production do you think is hardest to improve?” Connect students’ responses to the previous lesson on waste elimination. Explain that today’s success criteria are to articulate the main constraints of lean operational strategies and to propose realistic mitigation tactics.

1. Do‑now (5’) – Students write as many lean tools as they recall on sticky notes; share briefly.
2. Mini‑lecture (10’) – Review lean principles and common operational strategies using slides.
3. Table analysis (12’) – In pairs, examine the limitation table, discuss impacts, and complete a worksheet summarising cause‑effect.
4. Hybrid‑solution activity (15’) – Groups design a mitigation plan for one limitation and present their ideas.
5. Whole‑class debrief (8’) – Consolidate key take‑aways and address any misconceptions.

Recap the principal limitations and how hybrid approaches can balance efficiency with resilience. Ask each student to write one mitigation idea on an exit ticket. For homework, read the case study on Toyota’s JIT adaptation and prepare a short reflection on its relevance to today’s lesson.